Han In Carbonite: In the rubber

A little over a year ago, I purchased the HIC from FP. I didnt know if he would want it back before he moved from the area, so it sat in my basement waiting. Seeing as it seems FP is so busy he cant walk, and didnt express any interest in taking ol' han with him back to the land of rain and mountains, he became what appeared to be a permanent fixture.

Recently, a local mold company and I were discussing how to best make a mold of it. Well it became a challenge for both parties concerned, and low and behold, hes now sitting under his first layer of silicone.

We are trying to determine if we want to do full depth replications, or only 1 inch deep. At the minimum, I intend to make myself a copy, have the electronics boxes all the way around cut from aluminum, and have it cold cast in bronze, instead of the gray/silver.

I know there has been a few attempts to put a run together on these. Which as far as I can tell, have all failed. This one wont, even if its just a run of 1:)

I think that for a finished piece, were looking at around 300 to 500 _shipped_, and if you want to pick it up, no shipping obviously. This is for one in one of a few different meterials. On the list so far are:

1. Ultralite (think fishing lure material) resin.
2. Skin coat flex (resin, but with flex)
3. Flexible 80 resin (with foam backing)
4. Flexible 80 with no backing (can be rolled up for shipping.

Ill be doing a true cold cast bronze for myself, that will need to be buffed to shine (like the jango helmets).

The 1 inch deep cast is for my home office, to go under the class for my desk. I saw a pic of one around here somewhere that did that, so I figured it would be a good way to go.

Im estimating the mold to cost me $500-$800

Im estimating each piece will be 150 in materials, and im estimating shipping a 1 inch, rolled, or slized (on a ban saw to be re-put together at the end location) $50 and a full size 1 inch deep shipped $100-150

Id prefer to do these in a medium that doesnt break easily for the ones being shipped.

The local modl shop (which is a national mold shop) says they can get me great deals on shipping. We will see how that turns out.

The mold is going to take some serious time to build up. Expect pictures late next week of progress.

Let me know if your interested (I understand pending pics) but lets assume for the fun of it, that it turns out as clean as the rest of my projects and the price stays SHIPPED at 400-450 EDIT: Price ended up being 375 for black and 400 for silver shipped US. Roughly 40 more to europe, 80 to australia

YES!!!

PLEASE!!!!

Woo Hoo!

Im not sure how the whole would ship over seas, but I think a rubber rolled, or a sliced in 3's wouldnt be difficult at all:)

Probably ship for less than 100 bucks.

Castings of the detailed areas only may be an option?

Interested in how this works out.

Im working on getting cnc copies of the electronics parts on the sides, to make a nice clean mold.

I could supply an electronic piece to someone with a nice vac machine, and they could probably pull those alot cheater than me casting them.

Ideally though, the front where theres texture, would be cast and then cut down, to be inset into a box you would build yourself.

I put one together out of orange styrofoam from home depot, and then paitned it grey, with a face cast, and a cheaply made rest of body, and they carried it walking 10 miles no problem in a parade.

WOW !! HIR ?? That is an awesome idea Mike !!

I'm glad to see this finally getting off the ground. I couldn't be an Indian giver (seller) :lol

And yes, I'm walking kind of funny these days :cry

I think you've got what it takes to pull this off without a doubt. I for one, would be seriously interested in one made of rubber actually !!

You sure you've got the mold materials figured for that right though ?? It's probably based on how thick (how many layers your pouring before backing of course). The last person I think did this was upward of $1200. But I think he nearly poured a "slab" mold :wacko :lol

Watching with anticipation :thumbsup



FP

Yah brother, the local place now sells me all my mold materials at cost. Rubbers and resins:) Theya re going to do the build up each day for me. Ill have to get like a 5 gallon bucket of hs3, which is like 400 bucks. and some foam. Im guessing 750 ish for the materials for the mold.

I think secretly the owner wants one for himself, thats why they want to help make it:)

Yah the rubber will be cool. Im thinkign 10 lb soft foam backing on rubber. That way it will hold its shape unless pressed _hard_. Besides we all know the real problem with shipping these is they break. But in hard rubber? No such problems:)


The rubber is the same rubber the knees are in. So it should stay firm.

Hopefully no one interprets my comments above about you not taking him, as negative. Trust me, I wanted to keep him, but its like being a foster parent. Dont get too attached to the kids, cuz they might get yanked out from under ya.

There are fewer and fewer of these around these days. And im trying to do this at a dollar amount that people can afford. Because until youve had one you have no idea how cool it is:)

Ill get some shots as we move forward. I have a mold I made of the face down stairs, im going to play around with some different casting materials while I wait, to see what works best. Im going to start with a bronze cold cast (powder not filler)

Oh HELL yeah I'm interested! Han in rubber, rolled up would be flat out (har har) awesome. Then not only is it easy to ship, but easy as hell to store it until the whole rest of the box can be completed.
I might have missed it, but what color would it be cast in for the rolled up rubber?

Subscribing to this thread so I can be right on top of this progress. lol
This is great timing, I have to say! :)

huh. i think i'd have a hard time not getting one of those ;)

This is the project you've been talking about. I love it. Color me interested in one of these.

I seriously doubt i will have the cash to get one, but dang...I sure would like to!!!!!! I guess you could say I'm possibly interested!! Lol. That is however, a very modest price range!!! Better start saving my pennies!!! Look forward to pics!!!

In the hard rubber, it would be in black. Or a dark gray. The real piece is gray, not a bronze/metallic like in the movie. Its either made incorrect, or its the red lighting on bespin and jabbas palace that give it the red tint.

For the rubber casts, id probably back fill the hands and face and toes with flexi foam, so they keep their shape.

Ill make a hard rubber face cast this week, and post some pics to get a handle for it:)

Always wanted to have that trophy and considering I live in Ann Arbor pick up would seem prime. Just gotta raise the scratch here to afford it.

Quote:

---

Originally Posted by Stormrider

Ill make a hard rubber face cast this week, and post some pics to get a handle for it:)

---

Im getting SERIOUSLY excited now mate!!!

:cheering

I could probably pour one tonight with some spare materials I have laying around, just to get a feel. Depending on when vball gets over.

Quote:

---

Originally Posted by Stormrider

In the hard rubber, it would be in black. Or a dark gray. The real piece is gray, not a bronze/metallic like in the movie. Its either made incorrect, or its the red lighting on bespin and jabbas palace that give it the red tint.

For the rubber casts, id probably back fill the hands and face and toes with flexi foam, so they keep their shape.

Ill make a hard rubber face cast this week, and post some pics to get a handle for it:)

---

Awesome! Sounds great!
And yeah you do really see the color in Bespin of the really nice silverish gray over the color in Jabba's Palace.
And the backfilling sounds like a great idea too. I was wondering if the details like that would be hollow or filled in. So essentially, would the back be flat solid while the front has all the details in the rubber?

I guess I should just shush up and wait for pics than asking all these questions. LOL

Interested....Our local garrison table does'nt seem to have
a lot of static props. This would be a great way to help out
and provide more for ppl to look at. I love your work SR!

Ok first pull of my test mold. In rubber. I pulled a hard plastic and a 80 durometer rubber. One coat. Its a little thin, but backed with a 10 lb foam, would be perfect.

But of course, you tell me:) The pictures dont do it justice. Its cast in bronze cold cast rubber. Im thinking that outside of the amount of materials for each one, and the time consuming nature of sloshing/building it up, it shouldnt be all that difficult a project.

Boy, am I excited;) The pictures are the same piece btw. The first is a much better representation of the color, but taken with my iphone, so no flash or adjustments.


http://www.ampgaming.com/downloads/rubberhan.gif

Looks fantastic to me!!!
Now you've gone and made ME all excited. LOL

OOOHHHHHH Just want every Fett needs!!!

Wow am i excited, because as I do the math and work these, we may be able to get the full frontal SHIPPED for around $250-275

Which in my opinion is sort of insane. The downside, space in this run limited.

Ive gotten a few inquiries for a 'interest list.

So lets do this.

Full front details in 80 durameter rubber (like the fp knees I did) cold cast in BRONZE or GUNMETAL GRAY for UNDER $300 in the US (Outside actual additional shipping, could be around $40), TO YOUR DOOR interest list starts here:
---------------------------------------------------------------------------------

Im going expect to get 10-20 out MAX. And im keeping 3. One to build my ultralight, one to hang on my door in my office, and one to just keep. Please only sign up if your interested and want to buy one. I have done a lot of runs, and buy the materials for them, then the 'bailers' end up costing me a tun. These will be quite a bit for the materials, so serious people only.

And by 'full front' if you look at the pictures of a HIC, theres a distinct line where the front, carbonite, rough concrete looking areas, meets cold, s mooth steele. Im going to do the ENTIRE front details (square) area, all the way to the cold steel. which is 3 feet x 6.5 feet

PM sent

Absolutely 110% interested in this! Gunmetal Gray please!
Shipping to Abbotsford, British Columbia, Canada. Lemme know when, and I'll PM you the full address / details and PayPal. :)

Id be interested in just a face if you ever consider it. It look great next to my JB cast.

Do you want the face in rubber or hard resin fetts? Probably only cost like $25-30 shipped. Do you want it cast in silver? Bronze what?

Do you think you would offer just the hands and face? That would be really cool and would be a great starting point for building one for those who can't buy the whole cast.

if you can do face and hands as a set i'd love to go that route. otherwise i'm in for the full thing.

Hey M, just to confirm I am interested, that looks awesome.

Thanks bobby. maybe we can trade for a rocketpack or something.

Ok, I went to the mold shop today. we continued the silicone process.

We took off the front faceplate, and the side elec boxes. and decided to make a FULL MOLD of the entire thing. Ill be mainly pulling the front pulls. However, if someone wants a full mold of it, it can be made. But materials and shipping would mean probably local pickup only.

One coat a day for the next 5-9 days, and then it will be time to pull them.

Once its fully coated and we get ready to do the sleeve, ill take some pics.

Its massive:)

If the whole front panel was pulled in rubber, does that mean it can be bent/folded for shipping? Just curious.

Thats the point of the hardened rubber. I should be able to roll it up, and ship it without damaging it. The piece I poured in rubber was very resilient, once I get the mixture right. The cold cast stayed, it didnt 'flex or tear' where folded.

I should be able to get the shipping down to a tolerable, and get these in peoples hands for $300 or less, for the full fronts:) $50 more overseas.

But the prior shipping costs for shipping this piece was over $200 EACH, plus materials to crate. Huge difference.

Im in for whatever you can do for us international folks :)

full/in parts/ whatever :)

Dave

Ok, update. Have about 3 layers of rubber on this bady boy.

Toing to lay some material into the silicone tonight, to make it tougher, and then start the mother shell tomorrow.

http://www.ampgaming.com/downloads/han1.jpg

That is looking awesome.....and a trade sounds great.

Super B.A!

Okay...one of those will be mine! :D

I expect to be pouring them Wednesday. With pics of gunmetal and shipping Thurs, for those ready for them.

AWESOME!! Definately can't wait!

hey brother, count me in for one of those bad boys !

The molds done, but im working on the sleeve/support. Its a lot heavier than I thought (70 lbs of silicone!) so im going to need to take my time on it.

heres a pic of the finished silicone
http://www.ampgaming.com/downloads/han2.jpg

I'll have a nice big slice of that cake!

Looks great, 70lbs, hope you have a nice area to store it lol.

It will be easier to pour copies till the mold is dead, and store those, than it will to store the mold:)

I have ideas of how to make a FULL cast in rubber, and then plans to build an innersupport shell out of foam, so that it can be transported in a suit case, then 4 sheets of pink insulation foam bought, cut, and inserted:)

Im a tactical genius sometimes:)

lol Nice!

O_o stunning... could you ship it overseas?

Yes the overseas shipping shouldnt be terrible. Less than a hundred.

I think the final front casts will weight 10-20 lbs of hard rubber. And can be folded in thirds. So it should be possible to get these everywhere in the USA for 300 ish and worldwide under 400. Which is a steal considering.

Ill have pulls for post over the weekend.

m2

Can't wait!! ;)

oof :wacko

Looks like this is coming along nicely ;)

You tactical genius you :lol I'm diggin the idea of the full rubber cast with interior support for sure !

You're down with trades huh ? Hmmm ....

FP

For FP stuff, id trade my soul! muhahahaha

and so no one thinks im crazy, the blue you see, isnt clay, its an old platinum mold I Icut up to make keys:)

ive been doing this daily at Alumilite, which has some AWESOME products, and the best technical support, ever.

The director of business is Mike Faupel, and hes one of the coolest guys ever. He will sit and help you over the phone, any time, anywhere. I highly recommend dealing with them.

I have never had a bad experience with them.

www.alumilite.com

There will be a full tutorial on making this mold when its complete.

***...at last my hopes came true!

Since I wanted to have a HIC life size so bad (and I missed an offer over at the RPF), I am DEFINATELY in if you will ever do a run.

Is it possible to get one in solid resin (or fiberglass?), cut up into 3 or 4 sections in order to ship it overseas?

Shipping costs would be no issue since I want this so bad...

This is brilliant! I'm definately in!!!

Thanks!

Yes, I could mke it in resin. But the hard rubber, is like... the floor mats of your car. Its pretty hard. hard enough that if its glued down, you wont know its rubber. If you know anyone with my rubber knees, you know how hard it is.

These will be 'running' this week. The first one with photos should be up mid week. The shop closd (too big to do at my house) friday, befire I could do the last sections of sleeve.

Sent u a pm storm!

Looking great M.

Has there been a pull yet Storm? I'm quite giddy waiting to see what you've done here-awesome work in just a short timeframe!
Mike

No, I didnt like the hard coat, so I had to take a sheet of plywood, and build a 'rack system' to do the hardcoat with.

Ill post a pic. I need to run by the shop and get some rubber for some more knees anyway.

I'm still interested in one of these.

Awesome, cause theres gonna be about twice the cost in materials for this booger. But it should create some excelent repros.

Does that mean they are going to be 600 and not 300...interest may be waning since my wife is reading this too.

no absolutely not.

I wouldnt do that in any way shape or form.

Im shooting for 300 ish, give or take shipping cost.

I just need to sell more:)

Throw me on the list Brother! Now that I've got the wife working I can afford a little more...just like your carbine (insert Mr. Burns laugh and "Excellent":D).

As soon as there are some avaiable in a really rigid and stiff material (I don't want people say "hey that's rubber" when they touch it) I'm definately in...sry had to say this again :D

Price is not an issue for me...furtonately.

If the sections are cut up to let's say 3 or 4 pieces it wouldn't be a problem to ship.

I can pour you one in hard resin, its not a problem.

The plan is to pour on tues/weds this week and get photos up.

The delay is restarting the hard coat, and building a frame. Ill post a pic of the frame tonight or tomorrow and you'll understand:)

I think the rubber in 1/2 inch thick would be like car tire. Kinda hard to tell its rubber unless you know its rubber for those others that are worried.

I am also going to goof around with making rubber sections in hard resin, so it will 'fold' but am not 100% sure how that will work, but we will know soon!
m2

Hey M2
Glad to hear you're making progress and trying to keep the cost down.
Im really looking forward to Wed- cant wait to see.
Mike

The delay was us going back and building this, to better support the dissassembling of the hard shell.

http://www.ampgaming.com/downloads/mold3.jpg

There will be a complete tutorial on making this posted on completion. (Except the mistakes hehe:)

Yesterday before we started, did two more sides yesterday, two this morning.

It will be demolded this afternoon. Ill hopefuly be able to pour one before I go out of town tomorrow morning, if not, im going to ask Mike to pour oneand send me pics of it.

Should have pics by this weekend so people can commit or opt out, so I know how much material to order.

http://www.ampgaming.com/downloads/mold4.jpg

Cant wait Brother! Looks Awesome!

WOW i have only done smallish silicone moulds and they were hard enough to lay up. this is looking great. sadly though i think the cost of shipping this bad boy to Oz will kill me alone. though i know some convention holders that might be interested. awsome work so far.

I am also interested...


But i have a few questions.

1.- How accurate is it?

2.- When we get it, will we get the whole thing, including the sides with the panels?

3.- If you mail it rolled... will it keep straight after taking it out of the box? or we should build some kind of structure to glue it to...?

4.-Can we see pics of the original that you are using as a mold?


Thanks

Regards

Alfredo


PD: Sorry about my english...

Ahhh, i forgot.. GREAT JOB !!!!

Madrid -

I can help answer that one for Mike. It's as accurate as it's going to get actually :thumbsup The master is "my" former Illusive Concepts HIC. About as close as anyone will get to the real deal. It was an absurdly low number too. I think #87 of #500 ?? Mike can correct me on that one .. but it was low. And in MINT condition :thumbsup

Well, unless Mike beat the crapolla out of it after he picked up from my house :D

-Chris

Yeah, i remember that i was going to buy it ...... but it was not possible at the end. :(

But you still havent answer the rest of the questions...:lol


Thanks a lot Chris!!! :thumbsup

Regards :hug

Alfredo :fettesb

Well, I said I could help :D I can't answer the rest for Mike unfortunately. Sorry brother. And I think I misunderstood you too. I didn't realize you knew what the master was because you were asking for pics. I thought you were asking what the master was. Sorry about that. I feel a little silly now :lol

-Chris

Too tired for questions, but FP had it on the nose. Its his old one, it was mint (the molding process broke a finger tip off! so now its not:()

This thing is massive. the end rubber piece is 22 lbs:) 3.5 x 15 x 15.

It takes a full gallon kit of rubber or resin to pull one, havent tried resin, but im assuming the same as rubber.

Heres the pic you have all been waiting for.

Its me holding the heavy sucka up.
http://www.ampgaming.com/downloads/rubber.jpg

Ill post price breakdowns tomorrow.

It will be really close to what I originally thought. But ill break it all down, like I usually do.

Im off to sleepy sleep now.

Holy ****, that's awesome!! :)

Incredible!!!

It turned out great! As soon as you know if you do one in resin (perhaps strengthened with some fiberglass) plz let me know!

Also, I don't know how it can be done into 3 or 4 sections so that shipping is possible...

Anyway, I'm hooked up on this!

Ok heres the breakdown.

Im going to estimate the shipping in the us from 50 to 100 east and west coast for the rubber. There are still a few thing I need to look at, such as if the piece is rolled for 3 days, that it lays out flat and perfect. I may have to let them fully cure for a day or two before shipping to insure that no 'creasing happens'.

I dont believe that it should be created all the way to the edge like I did this time, I think it should go to where the 'texture' stops on the face.

It will save me a little resin, and logically, that 'part' is where the seam should be. It will make it easier to build 'full' props for people. I will make one out of foam core for people to see.

The boxes for the sides are going to be seperate. Im working on the cad to get clean ones cut. I can however make copies of the ones that shipped with it if people are interested. But I think personally they look nasty. Poor and un-crips detail.

So pricing, should be about this in the us.

$350 to $375 shipped for black add $40 if you want it gun metal. The gunmetal takes me more than an hour to put on, and costs about $20 bucks a cast.

The mold weighs 88 lbs. The shell was 10 gallon kits of shell coat.

50 lbs of silicone is around $500 and the 10 gallon kits are 60 each. When all was said and done, theres about $1400 in the mold its self.

Each gallon kit of rubber is $100 ish. Depending on how much I buy at a time.

so:
375 Each Piece
-75 for shipping
300
-100 for rubber
200
-100 for 8 hours work (the mold was about 100 hrs work ill devide by that by 20 copies)
100
-70 towards the mold costs

well you can see there will be little or no profit here. But I Intend to make one for myself, to make a desk out of, and then sell the master (which is another 1500 towards the total cost of project).

Lets just say, for those still interested and reading, its a deal.

So, im going to accept 8 orders to start, at a promised price of $399 or less shipped continental US. Add actual difference for international. Ill assess my costs and time after that and it may go up some. I feel bad I cant keep to the original $300 ish shipped, but the labor involved in making one, the concerns about it being too soft, so having to make it thicker, and the materials cost already inolved is through the roof. Each batch of rubber has to be mixed, and then degassed, and then spread properly. It is a tough process. And to be honest, im not even looking forward to doing the 10 (one I owe, one for me and 8 more).

I dont know how many copies this thing will make, and I dont want to oversell. I doubt ill redo the mold when it dies. It would probably kill me and sap my soul to do this again.

But its going to make a nice desk.

Ok, you can put me on the list to purchase. I want one. Excellent work!

I suppose I should add for another 200 - 300 ish, the rubber pulls can include the sides.

Which means you could build an internal structure to fill th entire thing. Extra shipping would apply.

And I wont get to pulling thse till monday. Its at the shop, and its closed:) Finally a vacatioN!

Looking great M, still interested!

I'm in...

LMK if it is possible the way I mentioned (only the "textured" area is enough, as you said, the flat border around the carbonite isn't necessary to cast).

Rigid cast in 3 or 4 resin sections, all shipped to europe.

If it isn't possible in any way to do it in resin or fiberglass backed up resin (into 3 or 4 sections), then I will settle down for a rubber cast...but resin would be top notch!

cheers

I can try a resin, however, I would have to cast it as one piece, and then slice it with a ban saw, id have to see what I could do.

Theres no way to cast it in three sections, unles I made some silicone dividers. Which wold be difficult.

I like the rubber version. The material like the knees would be great. Very firm.

Hi,

holy cow, great work ! :thumbsup

How much be will a rubber version in gun metal shipped to Germany ?

Really interested,

thanks

Florian

I am interesed in the rubber, including the sides. Could you please (whenever you have time) calculate shipping to Europe?

Thanks

Regards

Alfredo

Can't pass this up! PM sent to ya, brother! GREAT JOB on this! :thumbsup

Yep, like I said last week via PM before I left for vacation, definately want in for a gunmetal to Abbotsford, BC, Canada.

Because of the price of making and shipping these, its gonna have to be verified paypal to verified addresses. So verify yourself now! It ony takes a day or two!

Ill whip up the list soon.

Im going to whip up some silicone 'helpers' to help me make these things a little quicker.

Mondays the day it all happens.

M2

My verified paypal is

iamwoodenhorse@hotmail.com

Thanks

Alfredo

Quote:

---

Originally Posted by Bobby Fett UK

I like the rubber version. The material like the knees would be great. Very firm.

---

Me too!!!

Or if there was a possibility of a lite version like the helmet interiors :?

I say this because I wouldnt have the room for a fully boxed HIC but one that I could hang on the back of a door like a poster... :love

How much would the rubber weigh for shipping I wonder...

Dave

I could probably do a foam version like the inserts. The front in rubber is roughly 20-22 lbs. The hands and face and toes are pretty much solid. the rest is 1/3 to 1/2 inch thick.

The one you see is rubber, but im going to make dividers to only pour it to the edge of the texture next time. So i can use the extra rubber on the 'details'. To make a full sized replica, you would want to cut it at the texture and 'inset' it anyway. If you wanted to do it right.

Soooooo much to do, so littl time:)

:)

whatever is easier for you mate - Im interested!!!

Dave

PM sent!

Quote:

---

Originally Posted by Stormrider

I can try a resin, however, I would have to cast it as one piece, and then slice it with a ban saw, id have to see what I could do.

Theres no way to cast it in three sections, unles I made some silicone dividers. Which wold be difficult.

---

As I've said, if it's impossible without doing annoying extra work then I'll take a rubber version.

Just forget the resin and the cutting...I'll settle down on a rubber version.

My paypal account should be verified. Just lmk when you take payments (including an international shipping qoute).

cheers

To clarify the paypal thing, if you have bought from me before, it shouldnt be a problem.

I am getting quite a few 'never posted' and from 'zimbabwe' people messaging me.

There is a high level of tr4ust on this, with just shipping and materials costing me 200 right off the bat.

People with good reputations here need not worry, no reputation people shouldnt have a problem getting verified:)

I hope that clears it up.

I think the rubber will be a lot more firm and solid than people thing. Ill take more pics tomorrow.

Mike, I have a cousin's brothers badmitten teammate from Kzirkistan that wants one. PM me for his PP addy.

haha. Tell him I said:

Hurry Mr. Hello
I am for opportunity for him. Simply with haste paypal me $400 USD funds prompt. I immediately as can make appropriate shipment of said goods.

Quote:

---

Originally Posted by Stormrider

haha. Tell him I said:

Hurry Mr. Hello
I am for opportunity for him. Simply with haste paypal me $400 USD funds prompt. I immediately as can make appropriate shipment of said goods.

---

Sounds quite genuine.




:lol:lol:lol:lol:lol:lol:lol:lol

PM sent with a couple of questions.
Thanks!